Drive module for submersible autonomous vehicle

ABSTRACT

A drive module for submersible autonomous vehicles is disclosed. The drive module includes a propulsion element configured to engage and rotate against a surface, a motor configured to drive the propulsion element, and a controller configured to cause the motor to drive the propulsion element. The drive module also includes a housing configured to be removably, releasably coupled to the exterior of a submersible autonomous vehicle. The motor and the controller are disposed within the housing.

FIELD OF INVENTION

The present invention relates to the field of autonomous vehicles and,in particular, to a drive system or module for a submersible autonomousvehicle, and even more particularly, to an add-on drive system or modulefor a pool cleaning robot.

BACKGROUND

Autonomous vehicles are being introduced into an ever increasing numberof facets of daily life in order to automate various tasks, such ascleaning a pool, cleaning an indoor space, and maintaining a lawn.Additionally or alternatively, autonomous vehicles (also referred toherein as robots) may be used for entertainment, law enforcement, and awide range of other purposes. There are many types of autonomousvehicles; however, many of these autonomous vehicles, such assubmersible autonomous vehicles (e.g., pool cleaners) only include onetype or manner of propulsion at least because it is often noteconomically efficient to include a second type of propulsion (e.g., asecond drive system).

For example, since pool cleaners often require a pump or suction systemto clean a pool, it is often economically efficient (and efficient interms of space and size) to utilize the pump system for both cleaningand propulsion (e.g., as opposed to including a dedicated/second drivesystem). As a more specific example, U.S. Pat. No. 8,273,183,incorporated herein by reference, discloses an autonomous pool cleanerwith a water jet propulsion system that draws in water for both cleaningand propulsion. In order to utilize the drawn-in water to propel or movethe pool cleaner along a surface, the pump system discharges thedrawn-in water, as a pressurized stream, at an acute angle with respectto the surface. In the particular example of U.S. Pat. No. 8,273,183,the pressurized stream may be discharged in different directions tocontrol steering of the submersible autonomous vehicle. Similarly, manyindoor cleaning robots many only include two powered wheels. However,over time, these drive/propulsion systems will typically requiremaintenance, part replacement, or some other repair due to the wear andtear associated with repeated usage.

Unfortunately, since autonomous vehicles may be quite complicated andmay be pre-assembled, maintenance frequently requires an end-user totransport the robot to a mechanic, manufacturer, or some otherspecialized technical service provider familiar with the drive systemand/or the entire robot. Alternatively, an end-user may attempt todisassemble a robot and/or drive system with tools to try to assess andfix the problems on their own. However, often, an end-user can onlydisassemble a small portion of the robot (or a drive system) because themajor components have been coupled together with specialized tools(e.g., tools machined or developed specifically forassembling/disassembling this particular robot). Moreover, even if theend-user can determine the problem, a part or portion of the drivesystem may be broken and, thus, may require a user to identify and orderthe correct replacement part. Consequently, regardless of how anend-user attempts to resolve a maintenance issue, an end-user will oftenbe without a working drive system (and robot) for an extended period oftime. Since autonomous vehicles are typically unable to function withouta working drive system, this may render the autonomous vehicle uselessfor an extended period of time.

Moreover, as technology advances, new parts, programming, andconfigurations may be developed for robotic drive systems. Theseadvancements may improve various aspects of the robots (e.g., batterytechnology, ability to navigate different terrains, surfaces, increasedrobot efficiency or power, etc.); however, most robots cannot beupgraded and, instead, must be replaced to obtain a technologicalupgrade. In fact, many robots cannot even be reconfigured and, thus, areonly useful for certain, specific tasks (e.g., cleaning certain types orshapes of pools) and may require a user to buy different robots fordifferent tasks. For example, many pool cleaning robots are provided bythe manufacturer to the end-user in a compact, ready-to-use way, and theend-user is given little or no choice on how to configure of the robot.Then, if a user notices a problem with the drive system of the robot,the user has no options for adjusting the drive system to try toovercome the problem (and the user may also be unable to return orexchange the robot since the problems may only become apparent duringextended, post purchase, use).

In view of at least the aforementioned issues, a self-contained drivemodule that can be removably attached to an autonomous vehicle as areplacement or supplemental drive system is desirable.

SUMMARY

The present invention relates to a drive system or module for anautonomous vehicle and, in particular, a submersible autonomous vehicle.The drive module includes a drive motor that drives a propulsion element(e.g., a wheel or wheels, or an endless track) to propel the robot alongsurfaces (lawn, carpet, flooring, pool surfaces, pool deck, etc.),whether above or below water (e.g., submerged). Consequently, the drivemodule is mechanically isolated from any mechanical systems (e.g., geartrains) included within the body of an autonomous vehicle to which thedrive module is coupled (e.g., a “host” autonomous vehicle). Inaccordance with at least one embodiment of the present invention, thedrive module is also electronically isolated, insofar as the drivemodule need not be operatively coupled (via a wired or wirelessconnection) to any systems included within the body of a robot. Instead,a self-contained drive module can simply be removably coupled to anautonomous vehicle and operate independently. Alternatively, a drivemodule may be operatively and/or electronically coupled to systemsincluded within the body of a robot for specific requirements, such asto draw power from or supply power to electronic components includedwithin the body of the robot, and/or to retrieve/receive/communicatecontrol instructions to and from a control system included within thebody of the robot (or electrically coupled to the robot).

The present invention avoids problems posed by known autonomous vehicles(e.g., maintenance and configuration issues) by providing a modulardrive system that can be configured for many different autonomousvehicles. Consequently, if the drive system included on an autonomousvehicle malfunctions, requires maintenance, or is otherwise inadequatefor some reason (e.g., obsolete battery technology), the drive modulepresented herein can be coupled to the autonomous vehicle to supplementor replace the drive system of the host autonomous vehicle. Thisminimizes the downtime of autonomous vehicles with broken drive systemswhile also maximizing the flexibility of a particular autonomous vehicle(e.g., to complete a wide variety of tasks).

Put another way, the drive module presented herein allows existingautonomous robots and, in particular, submersible robots, to be easilyupgraded or reconfigured. As an example of an upgrade, the drive modulemay include the newest battery technology (e.g., smaller and/or morepowerful batteries) and may be utilized to upgrade the battery life ofan existing submersible, autonomous robot. The battery within the drivemodule could be a rechargeable battery that could, optionally, beremovable from the module and could be recharged in a charging stationvia a contact-based charging system or a contactless charging system. Atthe same time, the drive module presented herein provides a drive systemthat can be easily maintained and/or fixed without removing an entirerobot from service (e.g., a malfunctioning drive module of the presentinvention can simply be replaced with another drive module of thepresent invention).

As is described in further detail below, the drive module can be coupledto an autonomous vehicle with rapidly releasable coupling mechanisms,insofar as a rapidly releasable coupling mechanism includes any couplingthat can be rapidly achieved without the use of any specialized tools(e.g., without any tools) and without any special skills or knowledge,such that a rapidly releasable coupling mechanism can be engaged ordisengaged easily by an end-user. For example, a rapidly releasablecoupling mechanism may include snap-fitting mechanisms, tongue andgroove mechanisms, resilient mechanisms (e.g., detents, living hinges,etc.), half-turn or quarter turn latches and/or plug and socketmechanisms. Consequently, each drive module can be quickly and easilyreplaced by an end-user. In fact, in some embodiments, the components ofthe drive module presented herein may also be coupled together in amanner that allows each component to be individually removed from thedrive module without removing or disassembling other components tosimplify maintenance.

BRIEF DESCRIPTION OF THE DRAWINGS

To complete the description and in order to provide for a betterunderstanding of the present invention, a set of drawings is provided.The drawings form an integral part of the description and illustrate anembodiment of the present invention, which should not be interpreted asrestricting the scope of the invention, but just as an example of howthe invention can be carried out. The drawings comprise the followingfigures:

FIG. 1 is a front perspective view of an example autonomous swimmingpool cleaner including at least one drive module configured inaccordance with a first exemplary embodiment of the present invention.

FIG. 2 is a front perspective view of another example autonomousswimming pool cleaner including at least one drive module configured inaccordance with a second exemplary embodiment of the present invention.

FIG. 3 is a side, sectional view of the drive module of FIG. 2.

FIGS. 4A-C are side perspective views of a main body of the pool cleanerand the drive module of FIG. 2 and, collectively, FIGS. 4A-Cschematically illustrate mounting the drive module on the main body,according to an exemplary embodiment of the present invention.

FIG. 5 is a side, sectional view of the drive module of FIG. 1.

FIG. 6 is an exploded, side perspective view of the drive module of FIG.1.

FIG. 7 is a front, sectional view of the drive module of FIG. 1.

FIG. 8 is a flow chart illustrating operations of the drive module ofFIG. 1 during propulsion of an autonomous vehicle.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense but isgiven solely for the purpose of describing the broad principles of theinvention. Embodiments of the invention will be described by way ofexample, with reference to the above-mentioned drawings showing elementsand results according to the present invention.

Generally, the drive module presented herein includes a propulsionelement, such as a wheel or endless track, and a motor configured todrive the propulsion element. In some embodiments, the motor may becoupled to the propulsion element via a gear train, power train, orother such components. Additionally, the drive module includes acontroller that is operable to control the drive motor (e.g., to controlspeed and direction of a motor shaft). As is explained in further detailbelow, in some embodiments, the drive module may also alternately orconcurrently include a communications module that allows the controllerto communicate with a control system included in an autonomous vehicleto which the drive module is coupled (e.g., a host autonomous vehicle)and/or with other drive modules that are also coupled to the hostautonomous vehicle. Consequently, a drive module may receiveinstructions (via a wired or wireless connection) from, send feedback orcontrol instructions to, or otherwise communicate with the controlsystems or the other drive modules included on or within the body of ahost robot (e.g., a submersible, pool cleaning robot). Additionally oralternatively, the drive module may include memory with driveinstructions for controlling the drive motor.

Similarly, in some embodiments, the drive module may draw power frompower systems of a host robot, but in other embodiments, the drivemodule may include an internal power source. In still furtherembodiments the drive module may draw power from a host robot and alsoinclude an internal power source. Regardless, the drive module may beconfigured to power a motor, controller, and any other poweredcomponents included in the drive module. Additionally or alternatively,the drive module may be configured to provide power to electronicsystems included within the host autonomous vehicle. Consequently, ifthe drive module includes enhanced battery technology (as compared tobattery technology included on the existing host autonomous vehicle),the drive module may provide longer battery life, enhanced powerattributes, and any other such advantages afforded by the enhancedbattery technology to the existing host autonomous vehicle. As mentionedabove, the drive module's battery could be recharged in a chargingstation via a contact-based charging system or a contactless chargingsystem.

The drive modules presented herein in accordance with the presentinvention may be individually coupleable to an autonomous vehicle withrapidly releasable coupling mechanisms, such as snap-fit mechanisms, orother similar mechanisms, such that each drive module can easily beremoved from the main body (e.g., without disassembling other portionsof the autonomous vehicle). Consequently, an end-user may easily removea drive module for maintenance, replacement, or repair. Additionally, ifa robot has a broken drive system, a user may simply install (orreplace) a drive module onto the robot, instead of taking the robot outof service for an extended period of time for inconvenient and costlymaintenance. One particular embodiment for individually, releasablycoupling an exemplary drive module of the present invention to a hostautonomous vehicle is described below in connection with FIGS. 4A-C;however, this is merely an example and any rapidly releasable couplingmay be used to couple any embodiment of the drive module to a hostautonomous vehicle.

In many known submersible autonomous vehicles, components of theautonomous vehicle's drive system are distributed throughout theautonomous vehicle. Consequently, the drive systems are not removableand are difficult to repair. Alternatively, some submersible autonomousvehicles include components of a drive system (e.g., a motor) disposedexternally of a main body of the autonomous vehicle. However, thesedrive systems are often interconnected with systems included within theautonomous vehicle (e.g., external components are electrically connectedto a power source disposed within the main body of the autonomousvehicle) and/or not removable, let alone easily removable, from the mainbody.

Easy removal and replacement facilitate a do-it-yourself (DIY) approachand/or workaround for maintenance and repairs, while also allowing anend-user to reconfigure or upgrade an autonomous vehicle, if desired.For example, an end-user may easily reconfigure an autonomous vehiclebetween different drive configurations, perhaps to add rear-wheel driveto a front-wheel drive autonomous vehicle (thereby creating a four-wheeldrive vehicle) or to add traction propulsion to an autonomous vehicle(e.g., pool cleaner) with jet or fluid propulsion. As another example,the drive module could be used to provide the motive force for movingwater around inside the submersible autonomous vehicle (for cleaning apool, for example). In this example, a shaft extending outward fromwithin the body of the submersible autonomous vehicle could be matedwith the drive module where a bladed-member, like a fan blade, attachedto the end of the shaft within the body of the vehicle can be driven bythe motor within the external drive module. Thus, the body of thesubmersible autonomous vehicle need not include any internal motor orpump to operate. Put briefly, the drive module presented herein allowsthe end-user to design and configure an autonomous vehicle according totheir needs, encouraging a DIY approach for improvement andreconfigurations.

Now referring to FIGS. 1 and 2 for a high-level description of twoautonomous vehicles including exemplary drive modules in accordance withthe present invention. FIG. 1 shows an autonomous pool cleaner 10including a drive module 100, while FIG. 2 shows an autonomous poolcleaner 20 including a drive module 200. Although both of the depictedautonomous vehicles are submersible pool cleaners, it is to beunderstood that the drive modules described herein could also beinstalled on other types of autonomous vehicles configured to travelalong a surface (e.g., ground-based autonomous vehicles), such asautonomous vacuums, autonomous lawn mowers, etc. Moreover, featuresincorporated in one embodiment (e.g., drive module 100) could easily beincorporated into another embodiment (e.g., drive module 200), or viceversa.

The particular pool cleaner 10 shown in FIG. 1 typically includesfree-wheeling wheels and is driven (e.g., propelled) via water jetsexiting the top of the pool cleaner at sharp angles. The free-wheelingwheels contact the inner surfaces of the pool (walls and floor) and rollthereon as the water jets propel the pool cleaner 10. However, in theillustrated embodiment, the two front wheels have been replaced withdrive modules 100 configured as wheels in accordance with the presentinvention. The drive modules 100 are described in further detail belowin connection with FIGS. 5-7, but, generally, the drive modules 100 adda second propulsion system to the pool cleaner 10 that can be operatedtogether with the jet (fluid) propulsion system included in robot 10 oras an alternative to the jet (fluid) propulsion system. For example, thedrive modules 100 may drive the robot 10 in portions of the pool wherethe jet propulsion system may struggle (e.g., certain corners and/orwalls) and/or in situations where the jet propulsion system ismalfunctioning (e.g., when the jet propulsion system is clogged). As isalso described below in further detail, the drive modules 100 mayreceive power from, supply power to, and/or communicate with systemsincluded in the robot 10 in order to work together and/or as analternative to the jet propulsion system included in robot 10.

By comparison, the pool cleaner 20 shown in FIG. 2 is typically drivenby endless tracks that receive power from a motor disposed within a mainhousing of the pool cleaner 20, but have been replaced with orsupplemented by self-contained drive modules 200. The drive modules 200are described in further detail below in connection with FIGS. 3 and4A-C, but, generally, the drive modules 200 may include any components(e.g., a power source, motor, controller with drive instructions, etc.)needed to allow the drive modules 200 to propel the pool cleaning robot20 without interacting with any components or systems included in thepool cleaning robot 20. For example, the drive modules 200 may include acomplete power train housed therein and, thus, may be mechanicallyisolated from mechanical systems included in the pool cleaner 20.Despite the mechanical differences between drive module 100 and drivemodule 200, both drive modules may be sealed such that any electricalcomponents, gears, or other components that might be negatively impactedby exposure to water, are protected when the robots 10, 20 are submergedunder water.

Moreover, both drive modules may include a power source and necessaryprogram instructions to operate a power train and propulsion elementincluded therein, if desired. For example, the drive module 200 mayinclude an internal power source and program instructions stored inmemory, so that the drive module may also be operatively andelectronically isolated from systems included in the pool robot 20.However, despite these capabilities, in some embodiments, the drivemodules may be operatively and/or electronically coupled to systems of ahost submersible robot. For example, the drive module 200 may beelectronically coupled to a power system within the body of the robot 20in order to receive power from the robot 20 and/or the drive module 200may be operatively coupled to a control system within the body of therobot 20 in order to receive drive instructions from the control system.Moreover, these connections may allow a drive module (e.g., drive module200) to supply power and/or control instructions to systems includedwithin a host autonomous robot (e.g., a submersible pool cleaner withouton-board intelligence), possibly allowing the autonomous robot to bedetached from a tether or cord that attaches the cleaner to an externalsource of power and/or instructions.

FIG. 3 depicts the drive module 200 included in FIG. 2, according to anexemplary embodiment of the present invention. As mentioned above, thedrive module 200 is a self-contained drive module 200 and, thus,includes a controller 280 that is configured to control a motor 270 todrive a propulsion element 260. For example, the controller 280 maycontrol the rotational speed and rotational direction of a motor shaftfor any desirable periods of time. The controller 280 and motor 270 aredisposed within a housing 202 and the propulsion element 260 is disposedexternally of the housing 202. In at least some embodiments, the housingcomprises a water-tight enclosure and, thus, protects the controller280, the motor 270, and any other components disposed therein from waterexposure when the drive module 200 is utilized with a submersible robot.

In this particular embodiment, the propulsion element 260 is an endlesstrack extending around the housing 202 and the drive module 200 includesa gear train 272 and drive gears 274 configured, through well-knownmechanical coupling methods to impart motion from the motor 270 to thepropulsion element 260 so that the propulsion element 260 engages androtates against a surface to create a driving or propelling force. Thedrive module may also include a guide pulley 276 configured to stabilizethe endless track 260. However, in other embodiments, the drive module200 may include any elements or components to stabilize or support thepropulsion element 260 and impart motion from the motor 270 to thepropulsion element 260. Moreover, in other embodiments, the propulsionelement 260 may be any element that may engage and provide motion alonga surface. As an example, in some embodiments, the motor 270 may impartmotion directly to a propulsion element 260 configured as a wheel thatengages and rotates against a surface of a pool.

Regardless of the configuration of the motor 270 and propulsion element260, the controller 280 is generally configured to control the motor 270and, thus, is generally configured to control propulsion provided by thedrive module 200. The controller 280 may include a memory 282 and aprocessor 284. While the figure shows a signal block 284 for aprocessor, it should be understood that the processor 284 may representa plurality of processing cores, each of which can perform separateprocessing. Meanwhile, memory 282 may include random access memory (RAM)or other dynamic storage devices (e.g., dynamic RAM (DRAM), static RAM(SRAM), and synchronous DRAM (SD RAM)), for storing information andinstructions to be executed by processor 284. The memory 282 may alsoinclude a read only memory (ROM) or other static storage device (e.g.,programmable ROM (PROM), erasable PROM (EPROM), and electricallyerasable PROM (EEPROM)) for storing static information and instructionsfor the processor 284. In addition, the memory 282 may be used forstoring temporary variables or other intermediate information during theexecution of instructions by the processor 284. Although not shown, insome embodiments, the controller may include a bus or othercommunication mechanism for communicating information between theprocessor 284 and memory 282

The controller 280 may also include special purpose logic devices (e.g.,application specific integrated circuits (ASICs)) or configurable logicdevices (e.g., simple programmable logic devices (SPLDs), complexprogrammable logic devices (CPLDs), and field programmable gate arrays(FPGAs)), that, in addition to microprocessors and digital signalprocessors may individually, or collectively, are types of processingcircuitry. The processing circuitry may be located in one device ordistributed across multiple devices.

The controller 280 performs a portion or all of the processing steps ofthe invention in response to the processor 284 executing one or moresequences of one or more instructions contained in a memory, such asmemory 282. Such instructions may be read into memory 282 from anothercomputer readable medium. One or more processors in a multi-processingarrangement may also be employed to execute the sequences ofinstructions contained in memory 282. In alternative embodiments,hard-wired circuitry may be used in place of or in combination withsoftware instructions. Thus, embodiments are not limited to any specificcombination of hardware circuitry and software.

Put another way, the controller 280 includes at least one computerreadable medium or memory for holding instructions programmed accordingto the embodiments presented, for containing data structures, tables,records, or other data described herein. Examples of computer readablemedia are compact discs, hard disks, floppy disks, tape, magneto-opticaldisks, PROMs (EPROM, EEPROM, flash EPROM), DRAM, SRAM, SD RAM, or anyother magnetic medium, compact discs (e.g., CD-ROM), or any otheroptical medium, or any other medium from which a computer can read.

Embodiments presented herein include software stored on any one or anycombination of non-transitory computer readable storage media, forcontrolling the controller 280, for driving a device or devices forimplementing the invention, and for enabling the controller 280 tointeract with a human user (e.g., an end-user). Such software mayinclude, but is not limited to, device drivers, operating systems,development tools, and applications software. Such computer readablestorage media further includes a computer program product for performingall or a portion (if processing is distributed) of the processingpresented herein. The computer code devices may be any interpretable orexecutable code mechanism, including but not limited to scripts,interpretable programs, dynamic link libraries (DLLs), Java classes, andcomplete executable programs. Moreover, parts of the processing may bedistributed for better performance, reliability, and/or cost.

Still referring to FIG. 3, the drive module may also include a powersource/interface 294 configured to supply power to the controller 280and motor 270 and a communications module 292. As mentioned, in someembodiments, the drive module may be electronically and operativelyisolated. In these embodiments, the drive module 200 may not need acommunications module 292 and the power source 294 may be a battery orother such power source that is configured to supply power to thecontroller 280 and motor without receiving any continuous externalpower.

The communication module 292 may provide a two-way data communicationcoupling to a pre-existing controller within the body of the autonomousvehicle. Wireless links may also be implemented to communicativelycouple the communication module 292 to a pre-existing controller withinthe body of the autonomous vehicle and/or an external source ofinstructions (e.g., external to the host autonomous vehicle, such as abase station). In any such implementation, the communication module 292sends and receives electrical, electromagnetic or optical signals thatcarry digital data streams representing various types of information.

Generally, the communications module 292 may provide data communicationthrough one or more networks to other data devices. For example, thecommunications module 292 of a first drive module may provide aconnection to a communications module of a second drive module (e.g., ina master-slave configuration). Additionally or alternatively, asmentioned above, the communications module 292 may provide a connectionto a pre-existing system included within the body of an autonomousvehicle, such as a control system. The connection may be through a“wired” communication channel or a wireless communication channel orprotocol, such as BLUETOOTH®, or any other known form of wirelesscommunication feasible between sealed modules operating underwater, suchas optical communication, ultrasonic communication, and near-fieldcommunication. Even when utilized with a submersible robot, a wirelessconnection may provide sufficient connectivity between drive modules, adrive module and the host robot, etc., due to the proximity of theseparts.

In embodiments where the drive module 200 is electronically oroperatively coupled to an autonomous vehicle to which the drive module200 is coupled (e.g. a host autonomous vehicle), the powersource/interface may provide an electrical coupling to a power systemwithin the body of the autonomous vehicle and the communications module292 may operatively couple the drive module to systems included withinthe body of the autonomous vehicle to which the drive module 200 iscoupled. Such coupling may be achieved via a tether wire which passesfrom the drive module 200 into the body of the autonomous vehicle.Moreover, such a coupling may allow the drive module 200 to supply powerand/or send instructions to systems of the host autonomous vehicle. Forexample, if the host autonomous vehicle is a submersible pool cleanerthat receives power and/or control instructions from an external source(e.g., a pool cleaner without any on-board instructions or powersupply), the drive module 200 may replace or supplement the externalsource. Advantageously, this may increase the battery life of autonomousvehicle, allow for customized programming (e.g., by sending specificvoltages and/or pulses, at specific times, to a comparator,encoder/decoder, application-specific integrated circuit (ASIC), etc.included in the host robot), and/or allow a submersible robot to beuntethered from an external power source/controller.

Now referring to FIGS. 4A-C for a description of how a drive module 200of the present invention may be rapidly releasably coupled to anautonomous robot. In FIGS. 4A-C the drive module 200 is illustratedbeing coupled to a main body 22 of the robot 20; however, it is to beunderstood that this is merely one example of a rapidly releasableattachment and, in other embodiments, any drive module of the presentinvention may be rapidly releasably attached to an autonomous vehicle inany rapidly releasable manner so that other parts or assemblies includedin the autonomous vehicle need not be disassembled or rearranged (e.g.drive module 100 may be slid onto an axle and secured thereon with areleasable clamping mechanism). Consequently, if a drive module requiresmaintenance, repair, or replacement, the drive module can be easilyremoved and fixed by an end-user. Additionally, although not shown inFIGS. 4A-C, connecting a drive module of the present invention to anautonomous vehicle may also involve electronically orelectromagnetically coupling the drive module to the autonomous vehicle.

In the particular embodiment depicted in FIGS. 4A-C, a drive module 200is coupled to a main body 22 of the pool cleaner 20 by engaging thedrive module 200 with couplers 32 and an opening 34 included on a side30 of the main body 22. In order to engage the couplers 32, the drivemodule 200 includes clasps 252 configured to slide vertically into slotscreated by the couplers 32. In this particular embodiment, each drivemodule 200 includes four clasps 252, arranged in two pairs (to match thearrangement of couplers 32 included on the main body 22 of the poolcleaner 20); but in other embodiments any desirable arrangement may beutilized.

Once the clasps 252 have been inserted into the couplers 32, as isillustrated in FIGS. 4A and 4C (with FIG. 4A illustrating a portion ofthe main body 22 upside down and not properly aligned with the drivemodule 200, for illustrative purposes), the drive module 200 may bepressed against the main body to engage a detent 254 with the opening 34and create a snap engagement between the drive module 200 and the mainbody 22. Thus, the clasps 252 and couplers 32 may secure the drivemodule 200 to the main body 22 with respect to two directions (e.g., thex-direction and the z-direction) and the detent 254 and opening 34 maysecure the drive module 200 to the main body 22 with respect to a thirddirection (e.g., vertically, or with respect to the y-axis). Since thedetent 254 only resists a certain amount of force, the drive modules 200may be detached from the main body 22 by pulling the drive module 200laterally away from the main body 22 with a sufficient force todisengage the detent 254 from the opening 34. Then, the drive module 200may be slid downwards (or upwards if the pool cleaner 20 is upside down)by the end-user to remove the clasps 252 from the couplers 32 andrapidly decouple the drive module 200 from the main body 22 (withouttools).

In the particular embodiment depicted in FIGS. 4A-C, one drive module200 is shown being installed onto a first side 30 of a main body 22 ofthe pool cleaner 20, but it is to be understood that a second drivemodule 200 may be installed on a second side of the main body 22 in asimilar manner. In fact, in some embodiments, the drive module may besymmetrical so that the drive module 200 can be installed on either sideof an autonomous vehicle, such as pool cleaner 20. For example, in thedepicted embodiment, the detent 254 may be substantially centered on thedrive module 200 and features included on the drive assembly 400 may bemirrored about the detent 254.

That being said, in other embodiments, the detent 254 could be providedon the main body 22 and an opening equivalent to openings 34 could beincluded on the drive module 200. Similarly, in other embodiments, theclasps 252 could be included on the main body 22 and the drive module200 could include openings/couplers configured to receive the clasps.Still further, in other embodiments, the drive modules 200 may notinclude any clasps or detents and may be coupled to any portion of anautonomous vehicle in any manner that allows for rapid, removablecoupling, so that an end-user can quickly remove the drive module 200from an autonomous vehicle without tools.

Now referring to FIGS. 5-7, the drive module 100 illustrated in FIG. 1is shown in further detail to explain another embodiment of the drivemodule presented herein. In this particular embodiment, the drive module100 includes a controller 180, such as a printed circuit board (PCB),and motor 170 disposed within a housing 102. The controller 180 may besubstantially similar to the controller 280 and, thus, any descriptionof the controller 280 included above may also be applicable tocontroller 180. Thus, generally, controller 180 is configured to causethe motor 170 to drive a propulsion element 160 disposed externally ofthe housing 102.

In contrast with drive module 200, drive module 100 includes apropulsion element 160 that is a wheel 162 with a hub or rim (see FIG.6) and the motor 170 is configured to drive the wheel 162 and hub. Alsoin contrast with drive module 200, drive module 100 is configured to beelectronically and/or operatively coupled to the autonomous robot (e.g.,robot 10) to which the drive module 100 is coupled. Consequently, asshown best in FIG. 5, the drive module 100 includes a cable 182 out tothe robot. Controller 180 may receive instructions and power via cable182 and may, in turn, transmit power and instructions to the motor 170via cable 175.

In this particular embodiment, the drive module 100 is configuredspecifically for a submersible autonomous vehicle (e.g., a pool cleaner)and, thus, the controller 180 and motor 170 are sealed within thehousing 102. In particular, the motor 170 and controller 180 are sealedbetween an enclosure top 166 and an enclosure base 140. In the depictedembodiment, the enclosure base 140 and enclosure top 166 are sealedtogether with a sealing ring 144 disposed therebetween. The enclosurebase 140 and enclosure top 166 include openings to allow a motor shaftand axle to pass therethrough and these openings may be also be sealed,such as with sealing elements 142, 164, and/or 184. For example, element142 may be a motor shaft v-seal while elements 132 and 164 are sealswith ball bearings configured to receive an axle (with wired connectionsincluded therein) while epoxy seals 184 seal any exposed area in oraround the axle and bearings 134 and 164.

The shaft of motor 170 extends externally of the housing 102 formed bythe enclosure base 140 and enclosure top 166 and may engage and/orsupport a gear train that is configured to drive the propulsion element160. Specifically, the motor 170 drives a motor gear 134 disposedoutside of the housing 102 (e.g., on the opposite side of the enclosurebase 140 from the motor 170). The motor gear 134 drives a wheel gear 130configured to drive the propulsion element 160 (including wheel 162)about the motor 170 to create propulsion (thereby moving a pool cleanerto which the drive module 100 is coupled).

In some embodiments, the wheel gear 130 drives an axle (not shown), butin the depicted embodiment, the axle is rotationally fixed and thepropulsion element 160 is driven about the fixed axle. Similarly, insome embodiments, the housing 102 (formed by enclosure top 166 andenclosure base 140) rotates with or within the propulsion element, butin the depicted embodiment, the housing 102 is fixed with respect toaxle and propulsion element 160, thereby limiting the forces imparted onthe controller 180 and motor 170 and preserving the longevity of thesecomponents. In fact, in the particular embodiment shown in the Figures,an axle clamp 120 fixes the housing 102 (including the motor 170 andcontroller 180) to a fixed axle and, thus, the housing 102 remainsstationary while the propulsion element 160 rotates therearound. Thatbeing said, different axle configurations allow different driveconfigurations. For example, in at least some embodiments, a singlemotor can be used to drive multiple wheels disposed on the same axle. Tofacilitate some of these embodiments, the drive module 100 may beelectrically coupled to a host robot via a swiveling electricalconnection (e.g., when the entire drive module 100 rotates around anaxle),

FIG. 8 depicts a high level diagram of operations performed by a drivemodule (in accordance with the present invention) when the drive moduleis coupled to an autonomous vehicle. Initially, at step 802, adetermination may be made (e.g., by the controller of the drive module)as to whether the drive module is in communication with a control systemof a host autonomous vehicle, insofar as “host” simply denotes theautonomous vehicle to which the drive module is coupled. If the drivemodule is in communication with a control system of the host autonomousvehicle, the drive module may receive or retrieve drive instructionsfrom the control system (e.g., the on-board computer) of the hostautonomous vehicle and designate these instructions as the current driveinstructions at step 804. As an example, when drive module 100 iscoupled to an autonomous vehicle, a wired connection may be establishedbetween drive module 100 and the host autonomous vehicle and the drivemodule may retrieve or receive drive instructions.

By comparison, when the drive module 200 is coupled to an autonomousvehicle, the drive module 200 may not necessarily be in communicationwith control systems of the host autonomous vehicle (e.g., if a wirelessconnection cannot be established with the host autonomous vehicle). Ininstances where the drive module is not communicating with a controlsystem of a host autonomous vehicle, the drive module may retrieveinternal drive instructions (e.g., from memory) and designate theretrieved drive instructions as the current drive instructions at step806.

At step 810, a determination is made (e.g., by the controller) as towhether the drive module is in communication with another drive module.If the drive module is not in communication with another drive module,the drive module may drive the propulsion element, at step 814, inaccordance with the current drive instructions from step 804 or 806(e.g., the controller may drive the motor in a certain speed or in acertain direction, thereby creating specific propulsion, via thepropulsion element). Alternatively, if the drive module is incommunication with a second drive module, the current drive instructionsmay be adjusted based on the communication, at step 812. For example, ifan autonomous robot includes a first drive module disposed on the rightside of the robot and a second drive module disposed on the left side ofthe robot, the two drive modules may communicate to coordinate movementsand facilitate various driving patterns (e.g., in a master-slaveconfiguration). Once the current drive instructions are adjusted (e.g.,the drive module determines if it is a master or slave and respondsappropriately), the propulsion element(s) may be driven accordingly atstep 814. Then, the drive module may continue to check for furtherinstructions by monitoring for new connections.

To summarize, in one form, a drive module for autonomous vehiclesincludes a propulsion element configured to engage and rotate against asurface, a motor configured to drive the propulsion element, and acontroller configured to cause the motor to drive the propulsionelement. The drive module also includes a housing configured to beremovably, releasably coupled to an autonomous vehicle. The motor andthe controller are disposed within the housing.

While the invention has been illustrated and described in detail andwith reference to specific embodiments thereof, it is nevertheless notintended to be limited to the details shown, since it will be apparentthat various modifications and structural changes may be made thereinwithout departing from the scope of the inventions and within the scopeand range of equivalents of the claims. In addition, various featuresfrom one of the embodiments may be incorporated into another of theembodiments. Accordingly, it is appropriate that the appended claims beconstrued broadly and in a manner consistent with the scope of thedisclosure as set forth in the following claims.

It is also to be understood that the drive module described herein, orportions thereof may be fabricated from any suitable material orcombination of materials, such as plastic, foamed plastic, wood,cardboard, pressed paper, metal, supple natural or synthetic materialsincluding, but not limited to, cotton, elastomers, polyester, plastic,rubber, derivatives thereof, and combinations thereof. Suitable plasticsmay include high-density polyethylene (HDPE), low-density polyethylene(LDPE), polystyrene, acrylonitrile butadiene styrene (ABS),polycarbonate, polyethylene terephthalate (PET), polypropylene,ethylene-vinyl acetate (EVA), or the like. Suitable foamed plastics mayinclude expanded or extruded polystyrene, expanded or extrudedpolypropylene, EVA foam, derivatives thereof, and combinations thereof.

Finally, it is intended that the present invention cover themodifications and variations of this invention that come within thescope of the appended claims and their equivalents. For example, it isto be understood that terms such as “left,” “right,” “top,” “bottom,”“front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,”“interior,” “exterior,” “inner,” “outer” and the like as may be usedherein, merely describe points of reference and do not limit the presentinvention to any particular orientation or configuration. Further, theterm “exemplary” is used herein to describe an example or illustration.Any embodiment described herein as exemplary is not to be construed as apreferred or advantageous embodiment, but rather as one example orillustration of a possible embodiment of the invention.

Similarly, when used herein, the term “comprises” and its derivations(such as “comprising”, etc.) should not be understood in an excludingsense, that is, these terms should not be interpreted as excluding thepossibility that what is described and defined may include furtherelements, steps, etc. Meanwhile, when used herein, the term“approximately” and terms of its family (such as “approximate”, etc.)should be understood as indicating values very near to those whichaccompany the aforementioned term. That is to say, a deviation withinreasonable limits from an exact value should be accepted, because askilled person in the art will understand that such a deviation from thevalues indicated is inevitable due to measurement inaccuracies, etc. Thesame applies to the terms “about” and “around” and “substantially”.

The invention claimed is:
 1. A self-contained drive module forattachment to an exterior of a submersible autonomous vehicle, the drivemodule comprising: a propulsion element configured to engage and rotateagainst a surface; a motor configured to drive the propulsion element; acontroller configured to cause the motor to drive the propulsionelement; and a housing configured to be removably coupled to theexterior of the submersible autonomous vehicle, wherein the motor andthe controller are disposed substantially within the housing.
 2. Theself-contained drive module of claim 1, further comprising: a powersource configured to supply power to the controller and the motor. 3.The self-contained drive module of claim 2, wherein the drive module iselectrically isolated from electrical components within the submersibleautonomous vehicle.
 4. The self-contained drive module of claim 1,further comprising: a power interface configured to draw power fromwithin the submersible autonomous vehicle and deliver the power to thecontroller and the motor.
 5. The self-contained drive module of claim 1,further comprising: a communications module configured to establish atleast one of a wired or wireless connection with the submersibleautonomous vehicle.
 6. The self-contained drive module of claim 5,wherein the controller is configured to communicate, via thecommunications module, with a control system within the submersibleautonomous vehicle to retrieve drive instructions for the controller. 7.The self-contained drive module of claim 1, wherein the propulsionelement comprises at least one of a wheel and an endless tread.
 8. Theself-contained drive module of claim 1, wherein the controllercomprises: at least one processor configured to control the motor inaccordance with drive instructions.
 9. The self-contained drive moduleof claim 8, wherein the controller further comprises: a memory storingthe drive instructions, and the drive module is operatively isolatedfrom control systems within the submersible autonomous vehicle.
 10. Theself-contained drive module of claim 1, wherein the drive module ismechanically isolated from drive components within the submersibleautonomous vehicle.
 11. The self-contained drive module of claim 1,wherein the submersible autonomous vehicle comprises a pool cleaner. 12.The self-contained drive module of claim 11, wherein the submersiblepool cleaner includes a fluid propulsion drive system.
 13. A submersibleautonomous pool cleaner comprising: a main body including: an exteriorsurface; a fluid drive mechanism configured to propel the submersibleautonomous pool cleaner along a surface of a pool; and a control systemoperable to control the fluid drive mechanism; and a drive modulereleasably coupled to the exterior surface of main body, operativelycoupled to the control system and also configured to propel thesubmersible autonomous pool cleaner along a surface of a pool, the drivemodule comprising: a propulsion element; a motor configured to drive thepropulsion element; and a controller configured to cause the motor todrive the propulsion element.
 14. The submersible autonomous poolcleaner of claim 13, wherein the drive module further comprises: a powerinterface configured to draw power from the control system within themain body and deliver the power to the controller and the motor.
 15. Thesubmersible autonomous pool cleaner of claim 13, wherein the motor andthe controller are sealed within a watertight portion of a housing ofthe drive module and a motor shaft extends out of a sealed opening inthe watertight portion of the drive module housing to drive thepropulsion element.
 16. The submersible autonomous pool cleaner of claim15, wherein the drive module comprises a wheel and the wheel isreleasably coupled to an axle extending from the main body.
 17. A methodof driving a submersible autonomous vehicle comprising: removablycoupling a drive module to an exterior of a submersible autonomousvehicle, the submersible autonomous vehicle including an internalpropulsion system and the drive module including a propulsion element, amotor configured to drive the propulsion element, and a controllerconfigured to cause the motor to drive the propulsion element;establishing a communication connection between the drive module and thesubmersible autonomous vehicle; receiving drive instructions at thedrive module; and driving the submersible autonomous vehicle with atleast one of the drive module and the internal propulsion system inresponse to the drive instructions, wherein the controller causes themotor to drive the propulsion element when the drive instructionsindicate that propulsion from the drive module is required.
 18. Themethod of claim 17, where the drive module is a first drive module andthe method further comprises: removably coupling a second drive moduleto the exterior of the submersible autonomous vehicle; establishing acommunication connection between the first drive module and second drivemodule; driving the submersible autonomous vehicle with the first drivemodule and the second drive module based on the drive instructions.